PUMP-FUEL INJECTION
REMOVAL
CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.
WARNING: High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. Use extreme caution when inspecting for high-pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect for high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.
1. Disconnect negative battery cable.
2. Drain engine coolant. Refer to Cooling section.
3. Raise and support vehicle.
4. Disconnect and reposition engine coolant hose near rear of injection pump.
5. Remove timing belt. Refer to Engine-2.8L Diesel for procedures.
6. Remove injection pump sprocket mounting nut (2). Attach a typical 3-jaw gear/sprocket puller such as special tool 1023 and remove sprocket (1) from pump.
7. Disconnect high-pressure fuel line (4) at rear of pump by removing banjo bolt.
8. Disconnect high-pressure fuel line (2) at rear of pump by removing fitting at end of line.
9. Disconnect electrical connector at high-pressure fuel sensor (1).
10. Remove fuel injection pump mounting nuts (2).
11. Slide pump rearward from mounting studs.
INSTALLATION
CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.
1. Slip pump (1) over mounting studs.
2. Be sure pump is fully seated before tightening mounting nuts. Tighten injection pump mounting nuts (2) to 24 N·m (18 ft. lbs.) torque.
3. Position sprocket (1) to pump shaft and install nut (2) finger tight.
4. Install banjo bolt for fuel line (4) at rear of injection pump. Tighten bolt to 28 N·m (20 ft. lbs.) torque.
5. Install fuel line (2) and fitting to rear of injection pump. Tighten fitting to 28 N·m (20 ft. lbs.) torque.
6. Connect electrical connector to high-pressure fuel sensor (1).
7. Tighten injection pump sprocket nut (4) to 88 N·m (65 ft. lbs.) torque.
8. PUMP ALIGNMENT MARKS: Rotate pump gear (1) until marks (2) and (3) are aligned.
9. Install timing belt. Refer to Engine-2.8L Diesel for procedures.
10. Connect engine coolant hose near rear of injection pump.
11. Fill engine cooling system. Refer to Cooling section.
12. Lower vehicle.
13. Connect negative battery cable.
14. Start engine and check for fuel leaks.